High efficiency phase splitter

ABSTRACT

A phase splitter for separating a multiphase fluid into a relatively light phase and a relatively heavy phase includes a separator tube which comprises a fluid inlet through which the multiphase fluid enters the apparatus, a heavy phase outlet through which the heavy phase exits the apparatus and an inner diameter surface which defines a flow bore that extends between the fluid inlet and the heavy phase outlet. A swirl element positioned in the flow bore downstream of the fluid inlet causes the multiphase fluid to rotate and separate the heavy phase from the light phase. The light phase forms an elongated core which extends axially through the flow bore radially inwardly of the heavy phase from proximate the swirl element toward the heavy phase outlet. A core stabilizer is positioned in the flow bore between the swirl element and the heavy phase outlet and engages the distal end of the light phase core to thereby inhibit the light phase from exiting the apparatus through the heavy phase outlet.

BACKGROUND OF THE INVENTION

The present invention relates to an apparatus for separating amultiphase fluid, such as a mixture of oil and gas, into its constituentheavy and light phases. In particular, the invention relates to a phasesplitter which includes a core stabilizer for inhibiting the light phasefrom exiting through the heavy phase outlet in the event of fluctuationsin the multiphase fluid stream.

Phase splitters are used in the hydrocarbon production industry toseparate multiphase fluid streams into their different fractions orphases. For example, phase splitters are commonly used to separate theproduction fluid from a hydrocarbon well into separate streams of oiland gas so that these constituents can be transported and processedseparately. These phase splitters operate by rotating the multiphasefluid to create centrifugal forces which cause the heavy phase to movetoward the radially outer region of the fluid stream and the light phaseto form a core in the radially inner region of the fluid stream.

In prior art phase splitters, fluctuations in the flow of the multiphasefluid stream may cause the light phase core to become unstable. Thisinstability can be particularly severe near the distal end of the lightphase core and can result in an undesirably large quantity of the lightphase exiting the phase splitter through the heavy phase outlet. As aresult, the separation efficiency of the phase splitter is greatlyreduced.

SUMMARY OF THE INVENTION

These and other limitations in the prior art are overcome by providingan apparatus for separating a multiphase fluid into a relatively lightphase and a relatively heavy phase, the apparatus comprising a separatortube which comprises a fluid inlet through which the multiphase fluidenters the apparatus, a heavy phase outlet through which the heavy phaseexits the apparatus and an inner diameter surface which defines a flowbore that extends between the fluid inlet and the heavy phase outlet; aswirl element which is positioned in the flow bore downstream of thefluid inlet and which causes the multiphase fluid to rotate and separatethe heavy phase from the light phase, the light phase forming anelongated core which extends axially through the flow bore radiallyinwardly of the heavy phase from proximate the swirl element toward theheavy phase outlet; a discharge channel through which the light phaseexits the apparatus, the discharge channel being fluidly connected to aradially inner region of the flow bore; and a core stabilizer which ispositioned in the flow bore between the swirl element and the heavyphase outlet and which engages the distal end of the light phase core tothereby inhibit the light phase from exiting the apparatus through theheavy phase outlet.

In accordance with one embodiment of the invention, the core stabilizercomprises a cylindrical body which is positioned coaxially within theseparator tube and the body comprises a cavity which includes anupstream opening, a downstream end and an inner surface which convergesradially inwardly from the upstream opening to the downstream end. Theinner surface may converge generally linearly from the upstream openingto the downstream end. For example, the inner surface may converge at anangle of between about 15° and about 45°. More preferably, the innersurface may converge at an angle of between about 25° and about 35°.

In this embodiment of the invention, the body may comprise an outerdiameter which is between about 65% and about 85% of the inner diameterof the separator tube. In addition, the upstream opening may comprise adiameter which is between about 50% and about 70% of the inner diameterof the separator tube. Furthermore, the cavity may comprise an axiallength from the upstream opening to the downstream end which is betweenabout 100% and 150% of the diameter of the upstream opening. Also, theaxial distance between the downstream end of the swirl element and theupstream opening of the cavity is between about 4 times and about 5times the inner diameter of the separator tube.

In accordance with another embodiment of the invention, the body may besupported in the separator tube by a support ring which comprises anumber of axial holes through which the heavy phase flows.Alternatively, the body may be supported in the separator tube by anumber of radial fins which extend between the body and the separatortube.

In accordance with yet another embodiment of the invention, thedischarge channel may extend axially through the swirl element andcomprise a discharge opening in the downstream end of the swirl element.

In accordance with an alternative embodiment of the invention, theapparatus comprises a discharge body which is positioned coaxiallywithin the separator tube and includes a cylindrical portion, a conicalportion which comprises a base that is attached to or formed integrallywith an upstream end of the cylindrical portion, and a radial shoulderwhich is formed between the conical portion and the cylindrical portion,wherein the core stabilizer comprises the radial shoulder.

In this embodiment of the invention, the cylindrical portion maycomprise an outer diameter which is between about 70% and about 90% ofthe inner diameter of the separator tube. In addition, the radialshoulder may comprise a radius which is between about 6% and about 18%of the outer diameter of the cylindrical portion. Furthermore, theradial shoulder may comprise a radius which is between about 10% andabout 22% of the outer diameter of the base of the conical portion.Also, the axial distance between the downstream end of the swirl elementand the radial shoulder may be between about 4 times and about 5 timesthe inner diameter of the separator tube.

In accordance with still another embodiment of the invention, thedischarge channel extends axially through the discharge body andcomprises a discharge opening in the upstream end of the conicalportion. In this embodiment, the axial distance between the downstreamend of the swirl element and the discharge opening may be between about2 times and 3 times the inner diameter of the separator tube. Inaddition, the axial length of the conical portion may be between about 2times and 3 times the inner diameter of the separator tube.

Thus, the present invention provides a core stabilizer which engages thedistal end of the light phase core and inhibits the light phase fromexiting the separator tube through the heavy phase outlet even under theinfluence of fluctuations in the flow of multiphase fluid through thefluid inlet. As a result, the separation efficiency of the phasesplitter is greatly improved.

These and other objects and advantages of the present invention will bemade apparent from the following detailed description, with reference tothe accompanying drawings. In the drawings, the same reference numbersmay be used to denote similar components in the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional representation of a phase splitter inaccordance with one embodiment of the present invention;

FIG. 1A is an enlarged view of a portion of the phase splitter of FIG. 1showing more clearly the core stabilizer component of this embodiment ofthe invention;

FIG. 2 is an illustration obtained from a computational fluid dynamicssimulation of the phase splitter shown in FIG. 1;

FIG. 3 is an illustration obtained from a computational fluid dynamicssimulation of a phase splitter similar to the phase splitter of FIG. 1but without the core stabilizer component of the invention;

FIG. 4 is a cross sectional representation of a phase splitter inaccordance with another embodiment of the present invention;

FIG. 4A is an enlarged view of a portion of the phase splitter of FIG. 4showing more clearly the core stabilizer component of this embodiment ofthe invention;

FIG. 5 is an illustration obtained from a computational fluid dynamicssimulation of the phase splitter shown in FIG. 4; and

FIG. 6 is an illustration obtained from a computational fluid dynamicssimulation of a phase splitter similar to the phase splitter of FIG. 4but without the core stabilizer component of the invention;

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a phase splitter for separating outthe individual phases of a multiphase fluid. In the hydrocarbonproduction industry, for example, the fluid produced from a subterraneanwell may comprise a mixture of a relatively light phase such as gas anda relatively heavy phase such as oil. In this situation, a commonobjective is to separate the gas from the oil so that these separatephases may be transported and processed separately. Although theinvention can be used with a number of multiphase fluids and in avariety of industries, for purposes of simplicity it will be describedherein in the context of a device for separating gas from oil.

Referring to FIG. 1, one embodiment of a phase splitter in accordancewith the present invention, which is indicated generally by referencenumber 10, is shown to comprise an elongated separator tube 12 whichincludes a first or upstream end 14, a second or downstream end 16 andan inner diameter surface 18 which defines a flow bore 20 that extendsbetween the first and second ends. In use, the first and second ends 14,16 may be connected to corresponding sections of a pipeline which isconnected to, e.g., a hydrocarbon production facility.

In this embodiment of the invention, the multiphase fluid (representedby the arrow A) enters the separator tube 12 through a fluid inlet 22which is located in the first end 14, the relatively heavy phase(represented by the arrow B) exits the separator tube through a heavyphase outlet 24 which is located in the second end 16, and therelatively light phase (represented by the arrow C) exits the separatortube through a discharge channel 26 which in this illustrativeembodiment of the invention extends through a discharge pipe 28. Asshown in FIG. 1, the discharge pipe 28 includes a first section 30 whichextends axially through the flow bore 20 and a second section 32 whichextends transversely through the separator tube 12. The discharge pipe28 may be supported in the separator tube 12 by a gland nut 34 which isthreaded into a collar 36 that is attached such as by welding to theseparator tube.

The phase splitter 10 also includes a swirl element 38 which ispositioned in the flow bore 20 downstream of the fluid inlet 22. In theembodiment of the invention shown in FIG. 1, the swirl element 38 ismounted in the flow tube 12 and is connected to the upstream end of thedischarge pipe 28. As is well understood in the art, the swirl element38 sets the multiphase fluid into rotation, and the resultingcentrifugal forces acting on the multiphase fluid cause the heavy phaseto move to the radially outer region of the flow bore 20 and the lightphase to move to the radially inner region of the flow bore. The lightphase will thus form an elongated core 40 which extends axially throughthe flow bore radially inwardly of the heavy phase from proximate theswirl element 38 toward the heavy phase outlet 24. The light phase exitsthe flow bore 20 through the discharge channel 26, which in thisembodiment of the invention extends axially through the swirl element 38to a discharge opening 42 in the downstream end of the swirl element.

In prior art phase splitters, fluctuations in the flow of multiphasefluid through the fluid inlet 22 may cause the light phase core tobecome unstable. This instability can be particularly severe near thedistal end of the light phase core, i.e., the end of the light phasecore closest to the heavy phase outlet 24, and can result in anundesirably large quantity of the light phase exiting the separator tubethrough the heavy phase outlet 24.

According to the present invention, the phase splitter 10 includes acore stabilizer for stabilizing the light phase core 40. The corestabilizer, two exemplary embodiments of which will be described below,is positioned in the flow bore 20 between the swirl element 38 and theheavy phase outlet 24. In operation of the phase splitter 10, the corestabilizer engages the distal end of the light phase core and inhibitsthe light phase from exiting the separator tube 12 through the heavyphase outlet 24 even under the influence of fluctuations in the flow ofmultiphase fluid through the fluid inlet 22. As a result, the separationefficiency of the phase splitter is greatly improved.

In the embodiment of the invention shown in FIGS. 1 and 1A, the corestabilizer, generally 44, is shown to comprise a cylindrical stabilizerbody 46 which is positioned coaxially within the separator tube 12 andincludes a cavity 48 that extends partially therethrough. The cavity 48comprises an upstream opening 50, a downstream end 52 and an innersurface 54 which converges radially inwardly from the upstream openingto the downstream end. In the embodiment of the core stabilizer 44 shownin FIGS. 1 and 1A, the inner surface 54 converges generally linearlyfrom the upstream opening to the downstream end. For example, the innersurface 54 may converge at an angle a of between about 15° and about45°. More preferably, the inner surface 54 may converge at an angle a ofbetween about 25° and about 35°. Alternatively, the inner surface 54 mayconverge non-linearly so as to provide the cavity 48 with, e.g., ahemispherical or parabolic shape, among others.

The dimensions of the cavity 48 and the distance of the stabilizer body46 from the swirl element 38 depend on the flow rate of the multiphasefluid entering the phase splitter 10 and the approximate percentage oflight phase in the multiphase fluid. Although the ideal dimensions ofthe cavity 48 and distance of the stabilizer body 46 from the swirlelement 38 may be determined empirically for a given separationapplication, the inventors have discovered that for most applicationsthey may be determined using the following relationships. The innerdiameter D_(t) of the separator tube 12 depends in large part on theflow rate of the multiphase fluid entering the phase splitter 12. Oncethe inner diameter D_(t) of the separator tube 12 is determined, theouter diameter D_(b) of the stabilizer body 46 may be chosen to bebetween about 65% and about 85% of the inner diameter D_(t), thediameter D_(c) of the upstream opening 50 of the cavity 48 may be chosento be between about 50% and about 70% of the inner diameter D_(t), andthe axial length L_(c) of cavity from the upstream opening to thedownstream end 52 may be chosen to be between about 100% and 150% of thediameter D_(c) of the upstream opening. In addition, the axial distanceL between the downstream end of the swirl element 38 and the upstreamopening 50 of the cavity 48 may be chosen to be between about 4 timesand about 5 times the inner diameter D_(t) of the separator tube.

The stabilizer body 46 may be supported in the separator tube 12 by anysuitable means. In the embodiment of the invention shown in FIGS. 1 and1A, for example, the stabilizer body 46 is supported in the separatortube 12 by a support ring 56 which comprises a number of axial holes 58through which the heavy phase may flow. Alternatively, the stabilizerbody 46 may be supported in the separator tube 12 by a number of radialfins which extend between the body and the separator tube.

The effect that the core stabilizer 44 has on the light phase core 40can be seen by comparing FIG. 2 with FIG. 3. FIG. 2 is an illustrationobtained from a computational fluid dynamics (“CFD”) simulation of thephase splitter 10. As shown in FIG. 2, the core stabilizer 44 engagesthe distal end of the light phase core 40 and prevents the light phasefrom exiting the separator tube 12 through the heavy phase outlet 24. Bycomparison, FIG. 3 is an illustration obtained from a CFD simulation ofa phase splitter similar to the phase splitter 10 but without the corestabilizer 44. As is apparent from FIG. 3, the distal end of the lightphase core 40 is unrestrained. As a result, a significant percentage ofthe light phase is permitted to exit the separator tube through theheavy phase outlet.

Another embodiment of a phase splitter in accordance with the presentinvention is shown in FIGS. 4 and 4A. The phase splitter of thisembodiment of the invention, generally 100, is similar to the phasesplitter 10 described above in that it comprises an elongated separatortube 12 which includes a first or upstream end 14, a second ordownstream end 16 and an inner diameter surface 18 which defines a flowbore 20 that extends between the first and second ends.

In this embodiment, the multiphase fluid (represented by the arrow A)enters the separator tube 12 through a fluid inlet 22 which is locatedin the first end 14, the relatively heavy phase (represented by thearrow B) exits the separator tube through a heavy phase outlet 24 whichis located in the second end 16, and the relatively light phase(represented by the arrow C) exits the separator tube through adischarge channel 26 which extends through a discharge body 102. Thedischarge body 102 is positioned coaxially within the separator tube andincludes a cylindrical portion 104, a conical portion 106 whichcomprises a base that is attached to or formed integrally with anupstream end of the cylindrical portion, and a outlet portion 108 whichextends transversely from the downstream end of the cylindrical portionthrough the separator tube 12. The discharge body 102 may be supportedin the separator tube 12 by a gland nut 110 which is threaded into acollar 112 that is attached such as by welding to the separator tube.

The phase splitter 100 also includes a swirl element 38 which ispositioned in the flow bore 20 downstream of the fluid inlet 22. As inthe prior embodiment, the swirl element 38 sets the multiphase fluidinto rotation, and the resulting centrifugal forces acting on themultiphase fluid cause the heavy phase to move to the radially outerregion of the flow bore 20 and the light phase to move to the radiallyinner region of the flow bore. The light phase thus forms an elongatedcore 40 which extends axially through the flow bore radially inwardly ofthe heavy phase from proximate the swirl element 38 toward the heavyphase outlet 24. The light phase exits the flow bore 20 through thedischarge channel 26, which in this embodiment of the invention includesa discharge opening 114 in the upstream end of the conical portion 106.

In this embodiment of the invention, the cylindrical portion 104 of thedischarge body 102 comprises a diameter D₁, the base of the conicalportion 106 of the discharge body comprises a diameter D₂ which issmaller than the diameter D₁, and the core stabilizer comprises a radialshoulder 116 which is formed between the cylindrical portion and thebase of the conical portion.

As with the previous embodiment, the size of the core stabilizer 116 andthe axial spacing of the core stabilizer and the other components of theflow body 102 from the swirl element 38 depend on the flow rate of themultiphase fluid entering the phase splitter 100 and the approximatepercentage of light phase in the multiphase fluid. Although thesedimensions may be determined empirically for a given separationapplication, the inventors have discovered that for most applicationsthe cylindrical portion 104 may comprise a diameter D₁ which is betweenabout 70% and about 90% of the inner diameter D_(t) of the separatortube 12 and the core stabilizer 116 may comprise a radius R which isbetween about 6% and about 18% of the diameter D₁ of the cylindricalportion. In addition, the radius R of the core stabilizer 116 may bebetween about 10% and about 22% of the outer diameter D₂ of the base ofthe conical portion 106.

Furthermore, the axial distance L₁ between the downstream end of theswirl element 38 and the core stabilizer 116 may be between about 4times and about 5 times the inner diameter of the separator tube, theaxial distance L₂ between the downstream end of the swirl element andthe discharge opening 114 may be between about 2 times and 3 times theinner diameter of the separator tube 12, and the axial length L₃ of theconical portion 106 may be between about 2 times and 3 times the innerdiameter of the separator tube.

The effect that the core stabilizer of this embodiment of the inventionhas on the light phase core 40 can be seen by comparing FIG. 5 with FIG.6. FIG. 5 is an illustration obtained from a CFD simulation of the phasesplitter 100. As shown in FIG. 5, the core stabilizer 116 engages thedistal end of the light phase core 40 and prevents the light phase fromexiting the separator tube 12 through the heavy phase outlet 24. Bycomparison, FIG. 6 is an illustration obtained from a CFD simulation ofa phase splitter similar to the phase splitter 100 but without the corestabilizer 116. As is apparent from FIG. 6, the distal end of the lightphase core 40 is unrestrained. As a result, a significant percentage ofthe light phase is permitted to exit the separator tube 12 through theheavy phase outlet.

It should be recognized that, while the present invention has beendescribed in relation to the preferred embodiments thereof, thoseskilled in the art may develop a wide variation of structural andoperational details without departing from the principles of theinvention. Therefore, the appended claims are to be construed to coverall equivalents falling within the true scope and spirit of theinvention.

What is claimed is:
 1. An apparatus for separating a multiphase fluidinto a relatively light phase and a relatively heavy phase, theapparatus comprising: an elongated separator tube which comprises firstand second ends, a multiphase fluid inlet located proximate the firstend, a heavy phase outlet located proximate the second end, and an innerdiameter surface which defines a flow bore that extends between themultiphase fluid inlet and the heavy phase outlet, the heavy phaseoutlet being oriented coaxially with the flow bore; a swirl elementwhich is positioned in the flow bore downstream of the multiphase fluidinlet and upstream of the heavy phase outlet, the swirl element beingconfigured to rotate the multiphase fluid to thereby force the heavyphase radially outwardly toward the inner diameter surface of theseparator tube and the light phase radially inwardly into a light phasecore which extends axially through the flow bore from proximate theswirl element toward the heavy phase outlet; and a discharge body whichis positioned within the separator tube downstream of the swirl elementand upstream of the heavy phase outlet, the discharge body including acylindrical portion which is positioned coaxially within the separatortube and a conical portion which extends axially from an upstream end ofthe cylindrical portion toward the swirl element; the cylindricalportion comprising an outer diameter which is less than an innerdiameter of a radially adjacent portion of the separator tube to therebydefine an annulus between the cylindrical portion and the separator tubewhich is fluidly connected to the heavy phase outlet; the conicalportion comprising a downstream end which is connected to or formedintegrally with the upstream end of the cylindrical portion, an upstreamend which is axially spaced apart from the swirl element, an outersurface which converges radially from the downstream end of the conicalportion to the upstream end of the conical portion, and a dischargeopening which extends axially through the upstream end of the conicalportion to a discharge channel that extends axially through the conicalportion and the cylindrical portion; wherein the downstream end of theconical portion comprises an outer diameter which is less than the outerdiameter of the cylindrical portion to thereby define an annular corestabilizer shoulder which extends perpendicular to a central axis of theseparator tube; wherein during operation of the apparatus the corestabilizer shoulder engages the end of the light phase core to therebyprevent the light phase from flowing through the annulus and beingdischarged with the heavy phase through the heavy phase outlet.
 2. Theapparatus of claim 1, wherein the outer diameter of the cylindricalportion is between 70% and 90% of the inner diameter of the separatortube.
 3. The apparatus of claim 2, wherein the core stabilizer shouldercomprises a radius which is between 6% and 18% of the outer diameter ofthe cylindrical portion.
 4. The apparatus of claim 2, wherein the corestabilizer shoulder comprises a radius which is between 10% and 22% ofthe outer diameter of the downstream end of the conical portion.
 5. Theapparatus of claim 1, wherein the axial distance between the downstreamend of the swirl element and the core stabilizer shoulder is between 4times and 5 times the inner diameter of the separator tube.
 6. Theapparatus of claim 1, wherein the axial distance between the downstreamend of the swirl element and the upstream end of the conical portion isbetween 2 times and 3 times the inner diameter of the separator tube. 7.The apparatus of claim 6, wherein the axial length of the conicalportion is between 2 times and 3 times the inner diameter of theseparator tube.